Interlocking structural system for buildings



Feb. 21, 1967 B. F. BIRDWELL 3,304,630

INTERLOCKING STRUCTURAL SYSTEM FOR BUILDINGS Filed Dec. 13, 1963 FIG. 2

FIG. 7

INVENTOR. BENJAMIN F B/RDWELL BY 4/ United rates atent Orifice 3,304,689 INTERLGQKLNG STRUCTURAL SYTEPJ1 FQR BUELDINGS Benjamin F. liirdweli, Memphis, Tenn, assignor t Anel Engineering industries, incorporated, Winona, Miss., a

corporation of ltiississippi lFiled Dec. 13, 1963, Ser. No. 33%,397 8 claims. (Cl. 52-632) This invention relates to a structure for use in a building and, more particularly, relates to such a structure that is adapted to be used as various component parts of a building, such as, for example, a combined ceiling and roof or floor structure, wall structure, etc.

Thus, one of the objects of the present invention is to provide a structure that is adapted to serve as a clear span combined or integrated ceiling, beam, deck and/or insulation.

A further object is to provide such a structure that is adapted to serve as a load bearing wall.

A further object is to provide such a structure that is adapted to serve as a canopy ceiling and deck.

A further object is to provide such a structure that is adapted to serve as a permanent concrete form system for roofs, floors, and walls, thereby eliminating the previously used temporary forms and frames.

A further object is to provide such a roof and/ or floor system that is fire-proof.

A further object is to provide a roof an-d/ or floor system that is eflicient and structurally sound, yet which requires a minimum of materials, labor and time, thereby saving construction time and money.

A further object is to provide such a structure that includes a plurality of elongated channel-shaped pan members that are respectively interlocked in side-by-side relationship and which pan members provide the basic structure for a versatile product.

A further object is to provide unique means for interlocking the pan members so that quick field, snap-lock erection can be accomplished to save time and money and to assure best quality buildings.

A further object is to provide such interlocking means that gives stability to the structure.

A further object is to provide a cover or deck member which can be optionally used and interlocked with the pan members to provide a roof that eliminates the necessity for mop-on roof construction.

A further object is generally to improve the design and construction of structural systems for buildings.

The means by which the foregoing and other objects of the present invention are accomplished and the manner of their accomplishment will be readily understood from the following specification upon reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of one of the channelshaped pan members of'the present invention and a cover or deck member therefor which is shown in disassembled relationship.

FIG. 2 is a fragmentary sectional view through one form of the structure of the present invention, with the broken lines showing a modification thereof.

FIG. 3 is a fragmentary sectional view of another form of the structure of the present invention.

FIG. 4 is an enlarged fragmentary sectional view of a preferred form of the interlocking joint, illustrating the joining together of an adjacent pair of pan members and the joining together of cover members therewith.

FIG. 5 is an enlarged fragmentary sectional view showing a modified means of joining one edge of a cover member with a pan member.

' joined with the other pan members.

Referring now to the drawings in which the various parts are indicated by numerals, in the various forms of the present invention, the basic structure that is used is the channel-like member or pam 11, which is preferably formed from a sheet of light gauge metal, for example, 20 gauge steel, which is bent or shaped into the configuration best seen in FIG. 1. Pan 11 includes a substantially flat and rectangular mid-portion 13 and a pair of substantially parallel spaced side members 15, 17, respectively integrally attached to mid-portion 13 along the opposite side edges 19, 21 thereof, and which side members extend perpendicular in the same direction from mid-portion 13.

Unique interlocking means are provided adjacent the distal edges 23, 25 of side members 15, 17 and will be hereinafter described. It will be understood that the distal edges 23, 25 of side members 15, 17 are the respective edges of the side members which are remote from side edges 19, 21 and which, when the pans 11 are used as a ceiling or roof structure, are the upper edges of the side members 15, 17. In general, the interlocking means adjacent distal edge 23 includes a groove 27, and the interlocking means adjacent distal edge 25 includes a tongue 29. A plurality of pans l1 are arranged in sideby-side relationship to form the basic component of the structure of the present invention, with a pan 11, such as that shown in FIG. 1, having the tongue 29 thereof extending into the groove of a pan along one side thereof, and the groove 27 receiving the tongue of another pan on the opposite side thereof. In FIG. 7 is shown a plurality of the pans 11 joined together in the above-mentioned manner. In this figure, it will be noted that the pan 1]. to the left (only a fragmentary portion of which is shown) is in a position just before being joined with the other pans. Also, it should be noted that the configurations are diagrammatically shown as single lines and in open relationship for purposes of illustration, but it will be understood that in actual practice the surfaces are preferably close together, and the side members 15, 17 of adjacent pans 11 are in abutting relationship.

Referring now more specifically to the construction of tongue 29, the tongue is preferably integrally formed along the distal edge 25 as by bending the metal into the configuration best seen in FIG. 1. Thus, it will be seen that tongue 29 is substantially U-shaped in cross-section, with the U lying on its side when the pan ii is in a substantially horizontal position, as shown in FIG. 1. Thus, as considered in cross-section, the U-shaped tongue 29 includes a leg 31 integrally attached to the distal edge 25 and eX- tending perpendicularly outwardly from side member 17, another leg 33 in parallel spaced relationship to leg 31 and integrally interconnected therewith by a curved pOrtion 35. Leg 33, other than its integral formation with curved portion 35, is unattached and terminates in a distal edge 37, which is preferably turned up slightly, as best seen in FIG. 1. From the foregoing, it will be seen that tongue 29 extends substantially perpendicular away from the side member 17 and away from side member 15. Tongue 29 is resilient and is formed preferably of metal, as, for example, steel, and preferably is formed out of the same piece of metal as the remainder of pan 11. When tongue 29 is in an unrestrained position, as in the disassembled position shown in FIG. 1, the width thereof adjacent distal edge 37, that is, the width shown as at a in FIG.

1, is greater than the width of the mouth of groove 27, which is the dimension shown as at b in FIG. 1, so that when a tongue 29 is received in a groove 27, the tongue must be compressed in entering the groove, the importance of which shall be better understood in the description of the operation of the device to follow later in the specification;

Referring now more specifically to groove 27 and the means for forming same, adjacent the distal edge 23 of side member the metal is bent to form a first member 39 of substantially U-shaped cross-section with the U lying on its side when the pan 11 is horizontal, as in FIG. 1, and with the U shape being formed in much the same manner as tongue 29. Member 39 extends in substantially the same direction as tongue 29, but extends perpendicularly away from the inside of side member 15 towards side member 17 so that the mouth of groove 27 is adjacent the outside of side member 15. Thus, first member 39 includes a leg 41 integrally attached to side member 15 at distal edge 23 and extending perpendicularly inward from side member 15 towards side member 17, another leg 43 in parallel spaced relationship relative to leg 41, and a curved portion 45 integrally interconnecting legs 41, 43. Leg 43 extends from curved portion 45 and terminates in an edge that is doubled under, as best seen in FIG. 1, to establish a hem or abutment 47 inside of groove 27.

In assembling one pan 11 with another adjacent pan 11, a tongue 29 is moved from the disassembled position, as shown in FIG. 1, to an assembled position with the groove 27 of a pan adjacent thereto, as best seen by the interlocked joint as at 51 in FIG. 2 and FIG. 4. In moving a tongue 29 from said disassembled position to said assembled position, the tongue is received in the groove 27, and the distal edge 37 thereof is moved into contact with abutment 47, which compresses the leg 33. Continued movement of distal edge 37 past abutment 47 will allow the leg 33 to spring into a locked position with distal edge 37 being behind abutment 47, as best seen at the joint 51 in FIGS. 2 and 4. It will be understood that after this locking engagement has taken place, there is no possibility of accidental removal of tongue 29 from groove 27. Also, it should be pointed out that, in effect, each of the pairs of abutting side members 15, 17 of adjacent pans 11 form a beam with the interlocking joint 51 acting as a stabilizing support on the compression side of this beam. In other words, the joint 51, which is a slip joint, acts to give stability to the structure to prevent bending, twisting and/ or buckling of the above-mentioned beam.

After assembling a plurality of pans 11 in side-by-side relationship to establish the desired width of the structure, the next step in the assembly of the structure 53 of a preferred form of the present invention, as shown in FIG. 3, is to provide a concrete member 55 with reinforcing means embedded therein, and, also, a concrete slab 57 is preferably provided which is attached to the plurality of sections 59 that include pans 11 and concrete members 55. Concrete members 55 are preferably in the form best seen in FIG. 3 wherein it will be seen that the concrete members are in the form of an inverted U in cross-section and include depending leg portions 61, 63 and a connecting mid-portion 65 which establish a void portion 67 extending the length of sections 59 and which is surrounding by the respective inner surfaces 69, 71 of leg portions 61, 63, the surface 73 of mid-portion 65, and a portion of the inner surface 75 of mid-portion 13. It will be understood that void 67 not only reduces the weight of the concrete but also provides means for extending electrical conduits and/or other service connections and the like.

The preferable method of producing the heretofore mentioned concrete members 55, concrete slab 57, void 67, and reinforcing means is preferably as follows:

Forms 77, which are in the shape of an inverted U and which are preferably made of lightweight material such as paper, are respectively placed in pans 11. Next, reinforcing rods 79 are suspended in pans 11 as by means of wires 81 that are attached adjacent the upper ends thereof to reinforcing wire mesh 83 that is placed over the pans 11. The concrete is placed in the pans 11 around the forms 77 to establish the concrete members 55 when hardened. At the same pouring of the concrete, the concrete slab 57 may be formed over the wire mesh 83 and allowed to harden, which will establish a fiat surface 85 of the structure 53. It will be understood that the opposite or remote surface 87 of the structure 53 was heretofore established by the mid-portions 13 of the pans 11 which lie in substantially the same plane. If desired, insulation 89 may be provided, as best seen in the section to the right in FIG. 3, and which may be in the form of rock wool or other material to take up the space of void 67.

It will be understood from the foregoing description that structure 53 is adapted to provide a combined ceiling, deck, beams, and insulation all in one monolithic structure. Thus, it will be understood that the reinforced con crete members 55 and/or pans 11 serve as the beams; the surface 87 serves as the ceiling; the surface 85 serves as the roof, deck and/or floor; and insulation 89 and/or voids 67 serve as the insulation between an upper and lower room or between a room and the outside. If de sired, the surface 85 may be finished off as a roof by providing a mop-on deck of usual construction, which is shown as at 91 in FIG. 3.

A modified form of the present invention is shown in FIG. 2 wherein it will be seen that the sections 93 do not have the concrete therewith, but rather include pans 11, which are interlocked in the same manner as heretofore described, and preferably have insulation 95 provided therein to at least partially fill the pans. In addition, a deck or cover member 97 is provided for each section, with the cover member spanning the space between side members 15, 17 and spaced from the mid-portion 13. If desired, locking means in the form of helix drive screws 99 may be provided to extend through joints 51 and through the edge portions 101, 103 of the cover members 97, as best seen in FIG. 4. However, in most instances, screws 99 will not be necessary.

The edge portion 103 of each cover member 97 is preferably offset downwardly, as best seen in FIGS. 1 and 2, so that in assembled relationship, edge portion 103 extends into the space between legs 31, 33 of tongue 29. Edge 101 is preferably curved downwardly and inwardly, as best seen in FIGS. 1 and 2, so that in assembled relationship it fits over the distal edge of leg 43 of first member 39, as best seen in FIGS. 2 and 4. When the sections 93 are used as a combined ceiling and roof, it will be understood that no mop-on type of deck is needed, but the cover members 97 provide the roof. If desired, cover members 97 may be offset downwardly adjacent the midportions thereof, as shown in dotted lines 105 in FIG. 2, so that a so-called standing seam roof may be provided to prevent water from seeping in through the joints.

A modified form of the interlocking means for one edge of the cover members and the pans is shown in FIG. 5, wherein it will be seen edge portion 103 is provided with a dimple 107 which fits into corresponding dimples 109, 111 provided in tongue 29'. Another modification of the interlocking means is shown in FIG. 6, wherein it will be seen edge portion 103 is overlapped as at 113 and tongue 29" is provided with a roll crimp 115 therein which engages over overlapped portion 113 to prevent the accidental removal thereof. Also, if desired, another means for attaching the joints and cover members is by suitable well-known spot welding means. It will be understood that the opposite edges of the pans from those shown in FIGS. 5 and 6 are preferably as shown in FIG. 1.

Although, in the heretofore described examples, the structures of the present invention have been illustrated in horizontal position as combined ceiling and deck or floor structures, it will be understood that these structures may be turned vertically to serve as load bearing walls.

From the foregoing description, it can be seen that the basic component part of the present invention, namely, the pan members 11, which are interlockable by the unique interlocking joints, provide a very versatile product that can be adapted for many purposes. Thus, to mention a few uses and variations, they can be left uncovered, as shown in FIG. 7, for use as a ceiling and open pan roof; they can be covered with the cover members 97; they can be provided with insulation such as rock wool and the like; they can be provided with reinforced concrete; and they can be used as load bearing wall members. Also, from the foregoing description, it can be seen that the joints 51 lend stability to the compression sides of the beams formed by the side members of adjacent pan members, which are further stabilized by the use of the interlocked cover members 97 or the reinforced concrete. In addition, it can be seen that the pan members of the present invention can serve as permanent forms, thereby elimimating the previously used temporary forms and saving considerable money.

Although the invention has been described in some detail by way of illustration and example for purposes of clarity or understanding, it is to be understood that it is not to be so limited since changes and modifications may be made therein which are within the full intended scope of the invention as hereinafter claimed.

I claim:

1. A structural system for use in a building comprising a plurality of elongated sections; each of said sections comprising a channel-like member including a substantially flat and rectangular mid-portion, and a pair of spaced and substantially parallel side members respectively fixedly attached to said mid-portion along the side edges thereof and perpendicularly extending from said mid-portion in the same direction; said sections being arranged in side-by-side relationship with the adjacent side members of adjacent ones of said sections being in abutment with one another and with said mid-portions of said sections establishing one face of said structure, snap-lock interlocking'means respectively interconnecting said adjacent side members adjacent the distal edges of said adjacent side members, each of said sections additionally including a cover member interconnected with said side members and spanning the space between said side members adjacent the distal edges of said side members in spaced relationship with said mid-portion, said interlocking means including abutment means attached to one of said adjacent side members and edge means attached to the other of said adjacent side members locked behind said abutment means for preventing movement of said adjacent side members away from one another in a directional parallel to said mid-portion.

2. The structural system of claim 1 in which is included additional means for locking said cover member and said side members.

3. The structural system of claim 1 in which is included insulation means in said channel-like members.

4. A structural system for use in a building comprising a plurality of elongated sections; each of said sections comprising a channel-like member including a substantially flat and rectangular mid-portion, and a pair of spaced and substantially parallel side members respectively fixedly attached to said mid-portion along the side edges thereof and perpendicularly extending from said mid-portion in the same direction; said sections being arranged in sideby-side relationship with the adjacent side members of adjacent ones of said sections being in abutment with one another and with said mid-portions of said sections establishing one face of said structure, snap-lock interlocking means respectively interconnecting said adjacent side members adjacent the distal edges of said adjacent side members, each of said sections additionally including a concrete member and reinforcing means embedded therein received in said channel-like member, a concrete slab attached to said plurality of elongated sections remote from said mid-portions thereof to establish another face of said structure remote from said one face, said interlocking means including abutment means attached to one of said adjacent side members and edge means attached to the other of said adjacent side members locked behind said abutment means for preventing movement of said adjacent side members away from one another in a direction parallel to said mid-portion.

5. The structural system of claim 4 in which said concrete members respectively have the cross-sectional shape of an inverted U having depending leg portions with a void being provided therebetween.

6. The structural system of claim 5 in which insulation means is provided in said void.

7. A pan structure for use in a building comprising a substantially flat and rectangular mid-portion, a pair of spaced side members respectively fixedly attached to said mid-portion along the side edges thereof and extending substantially perpendicularly therefrom, a tongue formed along the distal edge of one of said side members, a first member of U-shaped cross-section including spaced legs with one of said legs being attached along the distal edges of the other of said side members and extending substantially perpendicularly therefrom and the other of said legs being unattached to provide a groove between said legs, said unattached leg of said first member being doubled under and terminating in an abutment in said groove, said tongue being substantially U-shaped in section and including spaced legs with one of said legs of said tongue being attached along the distal edge of said one of said side members and extending substantially perpendicularly therefrom and the other of said legs of said tongue being unattached and curved slightly away from said one of said legs of said tongue to terminate in a distal edge.

8. A structure for use in a building comprising a plurality of elongated channel-like members, each of said channel-like members including a mid-portion and a pair of spaced side members respectively fixedly attached to said mid-portion along the side edges thereof and upstanding therefrom, said channel-like members being arranged in side-by-side relationship with the adjacent side members of adjacent ones of said channel-like members being in abutment with one another to establish beams and with said mid-portions of said channel-like members establishing one face of said structure; and interlocking means respectively rigidly interconnecting said adjacent side members adjacent the upper distal edges of said adjacent side members to stabilize said beams and prevent bending, twisting and buckling thereof; each of said interlocking means including a tongue formed along the distal edge of one of the adjacent side members and a first member of U-shaped cross section including spaced legs with one of said legs being attached along the distal edge of the other of the adjacent side members and extending substantially perpendicularly therefrom and the other of said legs being unattached to provide a groove between said legs, said unattached leg of said first member being doubled under and terminating in an abutment in said groove, said tongue being substantially U-shaped in section and including spaced legs, with one of said legs of said tongue being attached along the distal edge of said one of the adjacent side members and extending substantially perpendicularly therefrom and the other of said legs of said tongue being unattached and curved slightly away from said one of said legs of said tongue to terminate in a distal edge, said tongue being in an assembled position relative to said first member with said tongue being received in said groove, said tongue being resilient and before assembly with said first member being wider adjacent the distal edge thereof than said groove whereby in assembling said structure said tongue must be compressed to be received in said groove, said distal edge of said tongue being disposed in a locked position behind said abutment to prevent accidental removal of said tongue from said groove.

(References on following page) References Cited by the Examiner UNITED STATES PATENTS Bloedow et a1 52588 Jabelonsky 52577 Inglee 52332 X Lucius 52588 Greulich 52404 X Gruber 52588 Miller 52577 X 8 FOREIGN PATENTS 1,249,543 11/1960 France. 1,311,704 10/ 1962 France. 1,330,351 5/1963 France.

946,261 7/ 1956 Germany. 776,547 6/ 1957 Great Britain.

FRANK L. ABBOTT, Primary Examiner.

M. O. WARNECKE, Assistant Examiner. 

4. A STRUCTURAL SYSTEM FOR USE IN A BUILDING COMPRISING A PLURALITY OF ELONGATED SECTIONS; EACH OF SAID SECTIONS COMPRISING A CHANNEL-LIKE MEMBER INCLUDING A SUBSTANTIALLY FLAT AND RECTANGULAR MID-PORTION, AND A PAIR OF SPACED AND SUBSTANTIALLY PARALLEL SIDE MEMBERS RESPECTIVELY FIXEDLY ATTACHED TO SAID MID-PORTION ALONG THE SIDE EDGES THEREOF AND PERPENDICULARLY EXTENDING FROM SAID MID-PORTION IN THE SAME DIRECTION; SAID SECTIONS BEING ARRANGED IN SIDEBY-SIDE RELATIONSHIP WITH THE ADJACENT SIDE MEMBERS OF ADJACENT ONES OF SAID SECTIONS BEING IN ABUTMENT WITH ONE ANOTHER AND WITH SAID MID-PORTIONS OF SAID SECTIONS ESTABLISHING ONE FACE OF SAID STRUCTURE, SNAP-LOCK INTERLOCKING MEANS RESPECTIVELY INTERCONNECTING SAID ADJACENT SIDE MEMBERS ADJACENT THE DISTAL EDGES OF SAID ADJACENT SIDE MEMBERS, EACH OF SAID SECTIONS ADDITIONALLY INCLUDING A CONCRETE MEMBER AND REINFORCING MEANS EMBEDDED THEREIN RECEIVE IN SAID CHANNEL-LIKE MEMBER, A CONCRETE SLAB ATTACHED TO SAID PLURALITY OF ELONGATED SECTIONS REMOTE FROM SAID MID-PORTIONS THEREOF OF ESTABLISH ANOTHER FACE OF SAID STRUCTURE REMOTE FROM SAID ONE FACE, SAID INTERLOCKING MEANS INCLUDING ABUTMENT MEANS ATTACHED TO ONE OF SAID ADJACENT SIDE MEMBERS AND EDGE MEANS ATTACHED TO THE OTHER OF SAID ADJACENT SIDE MEMBERS LOCKED BEHIND SAID ABUTMENT MEANS FOR PREVENTING MOVEMENT OF SAID ADJACENT SIDE MEMBERS AWAY FROM ONE ANOTHER IN A DIRECTION PARALLEL TO SAID MID-PORTION. 